Multi-body component optimization

Abstract

Techniques and systems for computer aided design of physical structures using an object splitting design process that optimize manufacturing efficiency are described. A described technique includes splitting, by a computer program, a three dimensional model of an initial object into an up skin region and a down skin region based on an analysis of draft angles along at least one surface of the three dimensional model of the initial object. The technique further includes producing, by the computer program, first and second three dimensional models of respective first and second objects in accordance with the up skin region and the down skin region to create separate first and second physical structures using one or more computer-controlled manufacturing systems such that the first and second physical structures are combinable to form a combined physical structure.

What is claimed is: 
     
       1. A method comprising:
 splitting, by a computer program, a three dimensional model of an initial object into an up skin region and a down skin region based on an analysis of draft angles along at least one surface of the three dimensional model of the initial object; and 
 producing, by the computer program, first and second three dimensional models of respective first and second objects in accordance with the up skin region and the down skin region to create separate first and second physical structures using one or more computer-controlled manufacturing systems such that the first and second physical structures are combinable to form a combined physical structure. 
 
     
     
       2. The method of  claim 1 , wherein splitting the three dimensional model of the initial object comprises determining a parting surface based on a connected series of points on the at least one surface of the three dimensional model of the initial object, each point of the series of points satisfying a condition defining a degree of perpendicularly between a manufacturing direction vector and a surface normal vector associated with the each point. 
     
     
       3. The method of  claim 1 , wherein the three dimensional model of the initial object comprises a structurally optimized geometry for the initial object, and wherein splitting the three dimensional model of the initial object comprises splitting, in accordance with a parting surface and without user interaction, the three dimensional model of the initial object, including the optimized geometry, into separate objects comprising the first and second objects, wherein the parting surface intersects an area situated between the up skin region and the down skin region. 
     
     
       4. The method of  claim 1 , comprising:
 receiving a hollow three dimensional model produced by a generative design process, wherein the three dimensional model of the initial object comprises the hollow three dimensional model produced by the generative design process. 
 
     
     
       5. The method of  claim 1 , comprising:
 obtaining a design space and design criteria, the design criteria comprising at least one manufacturing constraint, wherein the at least one manufacturing constraint supports manufacturing of the initial object using any of two or more manufacturing techniques; and 
 iteratively modifying, based on the design criteria, one or more outer shapes of a generative model within the design space to produce the three dimensional model of the initial object. 
 
     
     
       6. The method of  claim 5 , wherein the modifying comprises:
 computing shape change velocities for the one or more outer shapes of the generative model in a current iteration in accordance with the at least one manufacturing constraint, the at least one manufacturing constraint enforcing a minimum surface draft angle during the current iteration; and 
 updating the generative model using the shape change velocities. 
 
     
     
       7. The method of  claim 5 , wherein the two or more manufacturing techniques comprise an additive manufacturing technique, a subtractive manufacturing technique, and a die cast manufacturing technique, and wherein the at least one manufacturing constraint enables manufacturing of the initial object using any of the additive manufacturing technique, the subtractive manufacturing technique, and the die cast manufacturing technique. 
     
     
       8. The method of  claim 7 , wherein the modifying comprises using a constraint associated with the subtractive manufacturing technique for the generative model, and wherein the first physical structure, the second physical structure, or both the first physical structure and the second physical structure are manufactured using the die cast manufacturing technique, an injection molding manufacturing technique, or a combination thereof. 
     
     
       9. The method of  claim 5 , wherein the design criteria comprise a design objective that expands a transition zone between the up skin region and the down skin region. 
     
     
       10. The method of  claim 5 , wherein the three dimensional model produced by the modifying is a structurally optimized hollow design. 
     
     
       11. A system comprising:
 a non-transitory storage medium having instructions of a computer aided design program stored thereon; and 
 one or more data processing apparatus configured to run the instructions of the computer aided design program to perform operations comprising
 splitting a three dimensional model of an initial object into an up skin region and a down skin region based on an analysis of draft angles along at least one surface of the three dimensional model of the initial object, and 
 producing first and second three dimensional models of respective first and second objects in accordance with the up skin region and the down skin region to create separate first and second physical structures using one or more computer-controlled manufacturing systems such that the first and second physical structures are combinable to form a combined physical structure. 
 
 
     
     
       12. The system of  claim 11 , wherein splitting the three dimensional model of the initial object comprises determining a parting surface based on a connected series of points on the at least one surface of the three dimensional model of the initial object, each point of the series of points satisfying a condition defining a degree of perpendicularly between a manufacturing direction vector and a surface normal vector associated with the each point. 
     
     
       13. The system of  claim 11 , wherein the three dimensional model of the initial object comprises a structurally optimized geometry for the initial object, and wherein splitting the three dimensional model of the initial object comprises splitting, in accordance with a parting surface and without user interaction, the three dimensional model of the initial object, including the optimized geometry, into separate objects comprising the first and second objects, wherein the parting surface intersects an area situated between the up skin region and the down skin region. 
     
     
       14. The system of  claim 11 , comprising:
 receiving a hollow three dimensional model produced by a generative design process, wherein the three dimensional model of the initial object comprises the hollow three dimensional model produced by the generative design process. 
 
     
     
       15. The system of  claim 11 , wherein the operations comprise:
 obtaining a design space and design criteria, the design criteria comprising at least one manufacturing constraint, wherein the at least one manufacturing constraint supports manufacturing of the initial object using any of two or more manufacturing techniques; and 
 iteratively modifying, based on the design criteria, one or more outer shapes of a generative model within the design space to produce the three dimensional model of the initial object. 
 
     
     
       16. The system of  claim 15 , wherein the modifying comprises:
 computing shape change velocities for the one or more outer shapes of the generative model in a current iteration in accordance with the at least one manufacturing constraint, the at least one manufacturing constraint enforcing a minimum surface draft angle during the current iteration; and 
 updating the generative model using the shape change velocities. 
 
     
     
       17. The system of  claim 15 , wherein the two or more manufacturing techniques comprise an additive manufacturing technique, a subtractive manufacturing technique, and a die cast manufacturing technique, and wherein the at least one manufacturing constraint enables manufacturing of the initial object using any of the additive manufacturing technique, the subtractive manufacturing technique, and the die cast manufacturing technique. 
     
     
       18. The system of  claim 17 , wherein the modifying comprises using a constraint associated with the subtractive manufacturing technique for the generative model, and wherein the first physical structure, the second physical structure, or both the first physical structure and the second physical structure are manufactured using the die cast manufacturing technique, an injection molding manufacturing technique, or a combination thereof. 
     
     
       19. The system of  claim 15 , wherein the design criteria comprise a design objective that expands a transition zone between the up skin region and the down skin region. 
     
     
       20. The system of  claim 15 , wherein the three dimensional model produced by the modifying is a structurally optimized hollow design.